Busbar Design Guide

Busbar Construction: Types

Relevant physical properties of conductor materials used in busbar construction

Density @ 20°C CTE @ 20°C Thermal Conductivity @ 20°C

Metal Specification
(lb/in3) (x10-6m /m•°C) (W/m•K)

ASTM B-152
Copper 110 0.323 17 388
QQ-C-576

ASTM B-152
Copper 101 0.323 17 383 – 391
QQ-C-576

ASTM B-36
Brass 260 308 19.9 120
QQ-B-613

Aluminum 6061- T651 00.098 23.6 154 ASTM-B236

Busbar Construction: Types
Relevant electrical properties of conductor materials used in busbar construction

Thermal Coefficient of
Resistivity (ρ) @ 20°C Conductivity % IACS
Metal Resistivity (α) @ 20°C
Ω • sqmil/ft @ 20°C
(10-2/°C)

Copper 110 8.1 101 .393

Copper 101 8.1 101 .393

Brass 260 290.06 28 00.098

Aluminum 6061- T651 13.35 62 .423

Typical Busbar Sizes
If this program recommends sizes that do not fit into the ranges below, change either the number of conductors or
the section thickness of the busbar and recalculate the minimum cost solution

Thickness Range of Widths

1/16” 1/2-2”
3/8” 1/2 – 4”
3/16” 1/2 – 4”
1/4” 1/2 – 12″
3/8″ 3/4 – 12″
1/2″ 1 – 12″
3/4″ 4 – 12″
Busbar Construction: Lamination
Insulation Material Choice

Temp
Material Cost Colors Properties Notes
Index
Clear External Insulation
Mylar Low UL 94V-2 Coating 105°C
White Abrasion Resistant
Off White UL 94V-0 Polyamide Internal Insulation
Nomex Medium 220°C
Tan Paper High Dielectric Strength
UL 94V-0 Easy to Fabricate
FR1 Valox Medium Off White 125°C
UL 94V-0TMO High Dielectric
Yellow
Kapton Very High UL 94V-0 Film 240°C High Dielectric
Red
Tan 125°C/ High Voltages
FR4/Phenolic Medium UL 94V-0
Green 105°C Edge Protection
Black
Epoxy
Medium White UL 94V-0 150°C Edge Protection
Embedding
Amber
Complex Shapes, Holes
Powder Coating Low Many UL 94V-0 125°C
and Edges
Busbar Construction: Plating

Thermal Coefficient of
Metal Conductivity Resistivity (α) @ 20°C Specification
(10-2/°C)

Tin 13.6 .42 ASTM B545, MIL-T-10727

AMS 2403,AMS-QQ-N-290, QQ-N-

Nickel 11.8 .48
290

Silver 105.8 .38 ASTM B700

Solder Alloy 60/40 10 .40 AMS-P-81728, MIL-P-81728

Busbar Construction: Terminations

 Tabs  Studs  PEM  Fastons

 PCB  Connectors  Radsok®  Pins

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Busbar Construction: Terminations
Floating spacer Standard spacer Standoff spacer with
for optimal for easy leveling stud for easy
mechanical leveling and
tolerance connection (cable
shoe, resistor...)

Double spacer for Tapped spacer Compliance to

easy leveling and for leveling up standards for
connecting on both connecting point worldwide use
sides (snubber...)

Captive screw Threaded Casted link for

for easy and insert for fast reducing impedance
secure connecting and cost
mounting

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Busbar Construction: Terminations

Serted stud Fast-On® Wire Double bending

for universal tab terminal for tab for deep and
bolted bare wire cost effective
connection connection leveling

Extra cross- Pass-through Thick Semi rigid

section for connection insulant embossment
localized closing for for less
ampacity deep and constraints
reinforcement limited area

Integrated Embossment
barrier for for cost
increased effective
creeping leveling
distance